Intelligent production station and production method

ABSTRACT

One aspect related to design of systems and methods for manufacturing products that include technology in skilled areas is configuring a production station for use by an operator without specialized skills. The present invention contemplates an approach to designing a station configurable to perform one or more of incoming inspection, assembly, testing, and branding. A preferred approach includes verifying data associated with units prior to accepting them for incorporation, preventing incorporation of an incorrect unit, and guiding an operator in possible remedial action. This approach includes storing data in a server and making such data substantially instantly accessible to production stations once written in the server. Such data preferably includes software to configure the production station such that the operator need not have specialized skills. A production station designed using this approach is particularly useful in the manufacture of an outdoor unit of a split-mount microwave radio system.

CROSS-REFERENCE

This application is a continuation of U.S. nonprovisional applicationSer. No. 13/271,025, filed Oct. 11, 2011, and titled “IntelligentProduction Station and Production Method,” which claims priority to U.S.nonprovisional application Ser. No. 11/615,893, filed Dec. 22, 2006, andtitled “Intelligent Production Station and Production Method,” which areincorporated herein by reference.

COPYRIGHT NOTICE

A portion of the disclosure of this patent document contains materialthat is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the Patent and TrademarkOffice patent files or records, but otherwise reserves all copyrightrights whatsoever.

TECHNICAL FIELD

This invention is generally related to manufacturing and, morespecifically, to production of manufactured products, such as microwaveradios.

BACKGROUND

Manufacturing of products includes processing of subassemblies atmultiple production stations with each station designated, for instance,to one or more of incoming inspection, assembly, testing, calibration,and branding. Many products to be manufactured include multiplesubassemblies, one or more of which are capable of being configured inmultiple ways. Prior to accepting a subassembly for incorporation intothe product, the process ideally verifies data associated with thesubassembly, such as part number and configuration revision, to avoiderrors.

Such verification requires access to data associated with the bill ofmaterials (BOM) of the product to be manufactured, data frommanufacturing stages prior to the subassembly's arrival at theparticular production station, correct and actual configurationrevisions, etc. If the verification is not successful, the subassemblyis not accepted for incorporation into the product.

Some products include technology in particularly skilled areas. Examplesof skilled areas of technology include radio frequency and microwavetechnologies in products such as microwave radios, medical devices suchas X-ray, CAT (computed axial tomography) or MRI (magnetic resonanceimaging) machines, or fiber optics systems. Such products often includeone or more subassemblies capable of configuration. Errors in themanufacture of a product may result, after shipping, in unacceptableperformance, liability for failing to conform to regulations orstandards, or other anticipated or unanticipated problems. In someskilled areas of technology, such as those involved in medical devices,errors may cause physical harm.

Therefore, there is a need to consider the foregoing in the design ofmanufacturing systems and methods and the benefit of verifying dataassociated with subassemblies prior to accepting them for incorporationinto a product to be manufactured. One desired aspect of such designmight be to substantially increase accessibility of data and softwareused for verification purposes.

SUMMARY

The present invention addresses these and related aspects ofmanufacturing system and method design. In particular, the presentinvention contemplates design of systems for manufacture of units (e.g.,components, subassemblies) incorporating skilled areas of technology. Apreferred approach includes storing data associated with the productbeing manufactured, including the units thereof, in a server and makingdata in the server substantially instantly accessible at the productionstation. This also includes retrieving data from a unit received at theproduction station, comparing such data with server data associated withthe product, and verifying that the unit is a correct unit for thatproduct. This helps prevent incorporation into the product of anincorrect unit, such as an incorrect part number or an undesirableconfiguration. Preferably, this approach also includes guiding anoperator of a production station to take remedial action, such as toreplace the incorrect unit with a correct unit. The preferred approachfurther allows for remotely controlling the configuration of theproduction station. A system design using this approach is particularlyuseful in manufacture of an outdoor unit of a split-mount microwaveradio system.

This system design provides a number of possible advantages. Among themis the ability to configure, from a remote location, the tasks theproduction station is to perform and how it performs them. Theconfiguration includes remotely developing software for use on theproduction station and making such software available for download, orcausing such software to be downloaded, to the production station.Storing data retrieved, generated and updated from the productionstations in the server increases the accessibility of data and softwareneeded for manufacture and substantially reduces the likelihood oferrors. The system design allows for traceability of data associatedwith units incorporated into a manufactured product. The system designthus achieved is portable to and capable of being duplicated at any CM(contract manufacturer) with low requirements for maintenance andtraining of new operators.

Accordingly, for the purpose of the invention as shown and broadlydescribed herein, the present invention is directed to a system andmethod for manufacture of products. In accordance with one embodiment, aproduction station for processing manufactured products with one or moreunits that incorporate technology in a skilled area comprises: a dataretrieval component communicatively coupled to a unit of a manufacturedproduct and operative to retrieve data from this unit, the manufacturedproduct comprising at least one unit, including this unit, thatincorporate technology in a skilled area, a data access componentoperative to obtain from a server data associated with the manufacturedproduct, the associated data being substantially instantly accessible tothe data access component once written in the server, and a dataverification component operative to compare the retrieved data with theobtained data, and to generate an output based on the comparison,wherein the output indicates whether this unit should be accepted forprocessing or not.

Such production station may be configured to perform one or more ofincoming inspection, assembly, testing, branding, and post functionaltesting of the manufactured product. It may also be configured for beingoperated by a person who is unskilled in the area of technology. Theconfiguration may be achieved by obtaining from the server andinstalling on the production station software, instructions, andspecifications that have been developed and written in the server.Installation may be initiated at the production station or remotely. Theproduction station may further include a data generation component togenerate new or updated data, and a data writing component to write theobtained data and the generated data to the unit, and to write theretrieved data and the generated data in the server. The station mayalso include an interface component to communicate with (e.g., transferdata to and from) a peripheral device such as a printer or a datalogger.

A variation of the production station may include means for retrievingdata from a unit of a manufactured product comprising at least one unit,including this unit, that incorporates technology in a skilled area,means for obtaining from a server data associated with the manufacturedproduct, such data being substantially instantly accessible to suchmeans once written in the server, and means for comparing the retrieveddata with the obtained data, and for generating an output based on thecomparison, wherein the output indicates whether this unit should beaccepted for processing or not.

In accordance with another embodiment, a method for processingmanufactured products with one or more units that incorporate technologyin a skilled area comprises: obtaining from a server data associatedwith a manufactured product that is being manufactured and comprising atleast one unit that incorporates technology in a skilled area includingthis unit, the data associated with the manufactured product beingsubstantially instantly accessible once written in the server,retrieving data from the unit, comparing the data retrieved from theunit with the data obtained from the server, and generating an outputbased on the comparison, wherein the output indicates whether this unitshould be accepted for processing or not.

Such method may further include processing the unit, generating data,and writing the generated data in the server, to the unit, or both. Theprocessing may include performing one or more of incoming inspection,assembly, testing, branding, and post functional testing.

In accordance with yet another embodiment, a method for processingmanufactured products with one or more units that incorporate technologyin a skilled area comprises: configuring a production station to performa production function on a manufactured product, wherein the productionstation can be operated by a person who is unskilled in an area oftechnology incorporated in the manufactured product and whereinconfiguring includes obtaining from a server software, instructions, andspecifications associated with the production function, the software,instructions, and specifications having been developed and written inthe server, and installing and executing the software, instructions, andspecifications on the production station.

In these embodiments, various possible attributes may be present. Thedata retrieval component may include a scanner, a bar code reader, akeyboard, a key pad, a pointing device such as a mouse, a voicerecognition device, or a combination thereof. The unit may comprise anintermediate frequency, radio frequency local oscillator, transceiver,power module, diplexer, or mechanical subassembly. The obtained data mayinclude read-only data, read-and-write data, or both. Furthermore,portions of either type of such data may be designated restrictedaccess.

One application for these manufacturing systems is in the manufacture ofa wireless radio system, particularly one that operates in the microwavefrequency range. Thus, the systems and methods may be adapted formanufacture of an outdoor unit of a split-mount wireless radio system.

These and other features, aspects and advantages of the presentinvention will become better understood from the description herein,appended claims, and accompanying drawings as hereafter described.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate various aspects of the inventionand together with the description, serve to explain its principles.Wherever convenient, the same reference numbers will be used throughoutthe drawings to refer to the same or like elements.

FIG. 1 illustrates a production station according to one embodiment ofthe invention.

FIG. 2 illustrates a server according to one embodiment of theinvention.

FIG. 3 is a flow diagram of a method for manufacturing productsaccording to one embodiment of the invention.

FIG. 4 is a flow diagram of a method for assembling products accordingto one embodiment of the invention.

DETAILED DESCRIPTION

As mentioned, the present invention contemplates a design approach formanufacturing products comprising multiple units. The design may beimplemented as a production station. A production station is part of amanufacturing process and may be positioned at one of many stages in theprocess flow. Its main functions may generally be divided into twocategories, namely control over the product being manufactured, andcontrol over the configuration of the station itself.

Functions related to control over the product include verifying dataassociated with units prior to accepting them for incorporation into theproduct. Upon receipt of a unit, the production station obtainsinformation from a server. The information may be associated with theunit as well as with the product. Examples include a BOM (bill ofmaterials) for the product to be manufactured, and the part number andconfiguration of correct units according to the BOM. If the unit is acorrect unit for the product, the production station also verifies thatprocessing at prior stages in the process flow is complete. If theverification is successful, the unit is accepted. If not, the productionstation typically displays an error message to the operator and helpsprevent incorporation of the unit into the product.

The production station may also guide the operator to take remedialaction. For example, if the unit fails verification because the softwarerevision is incorrect, the operator may be guided to have the unitreconfigured, for example, by having a different software revisioninstalled on the unit. Reconfiguration may be performed on a separateproduction station or on the same production station configured toperform more than one set of functions, including reconfiguration. Ifthe unit fails verification because the hardware configuration isincorrect, the operator may be guided to replace the unit with aproperly configured unit.

During processing of the unit, the production station collects data. Thestation may write collected data in the server, to memory in the one ormore units incorporated in, or to be incorporated into, the product, orin both the server and to the unit. Collected data may include, forexample, a calibration file to be used at a stage following a productionstation configured as an assembly station.

The second category of functions includes control over the configurationof the production station itself. As noted, the production station mayinclude multiple functions, for instance, incoming inspection andtesting, or assembly and calibration. Even if the station performssubstantially only one function, its configuration may depend on thefunctions to be performed. For example, a station may be configured toassemble microwave radio systems one week and to test medical devicesthe following week. The company may also wish to alter the functions ofthe production station, for example, by adding, deleting or modifying aprocess step. To that end, the production station may download andinstall from the server revised software, instructions, andspecifications to be used on the station itself. Alternatively, downloadand installation may be initiated from a remote company location.

A company may be an entity for which the products are beingmanufactured, and it may be the entity that drives demand for productsto be manufactured by a CM (contract manufacturer) and that pays the CMfor such manufactured products. A company may be the entity owning theproduct design. Such company may also be the entity for which aparticular product is being manufactured under OEM (original equipmentmanufacturer) branding. A company may perform its own manufacturing, forexample, at its own manufacturing plant. In such a case, there is nothird party CM, and the company and the CM may essentially be one andthe same entity. In other situations, the company and the CM may bedifferent entities but belong to the same parent entity. For example,the company may be a U.S.-based subsidiary and the CM a China-basedsubsidiary of the same parent entity. In such a situation, whether thecompany and the CM are treated as two different entities or as a singleentity may depend on how demand is driven, payments are made, andconfidential and proprietary information is shared between the twosubsidiaries. A company and a CM are typically, but not necessarily,separate from suppliers of components and subassemblies to beincorporated into manufactured products and from suppliers of theequipment used in the manufacturing process. This may also apply tocustomers, i.e., entities purchasing the manufactured product from thecompany.

The preferred approach to designing a system for manufacturing productstherefore includes controlling the manufacturing process and preventingincorporation of an incorrect unit. This approach also includes guidingthe operator to take remedial action, if possible. The approach willpreferably achieve the goal of substantially increasing accessibility ofdata by storing data in a server and making the design portable tomultiple manufacturing plants. A design using this approach isparticularly useful in the manufacture of an outdoor unit of asplit-mount microwave radio system.

This design approach has taken into consideration the beneficial aspectsas well as deficiencies of various manufacturing system designs. Onesuch design may include manually collecting, on paper, data associatedwith the unit. For example, data collected manually may be logged on atraveler card that follows the unit on the manufacturing line, with thecard being stamped at each production station and capable of beingannotated by the operator. The card is typically archived and may beretrieved to review the data at a later time. Other data may becollected electronically, for example, on a local computer (e.g.,coupled to a stand-alone production station) or in one or more databaseson a computer system.

Alternatively, such design may include developing, at companydevelopment headquarters, new revisions of software, instructions, andspecifications to be used on the production station. Once released, suchnew revisions may be transferred, for example, to a remote manufacturingplant (e.g., a CM's plant) via mail (e.g., on CD-ROM), e-mail, FTP (filetransfer protocol), or the like.

As a further alternative, such design may include manual verificationthat the proper part number, configuration, branding, and so forth areused during the manufacture. A human error in the verification may notnecessarily lead to the manufactured product's failing subsequent tests,depending on which incorrect unit or incorrect configuration wasactually used. A product thus manufactured, even if it passesmanufacturing tests, may nonetheless fail in the field.

Moreover, in some design approaches, a customer's order may be filled byfirst manufacturing all products in a single (e.g., predefined)configuration. All or a subset of such manufactured products may then bereconfigured to conform to, for example, a downgrade in the softwarerevision with such products being later used as spares or replacementsfor the customer's existing installation of products. Another subset maybe reconfigured to private labeling. The foregoing approaches eachaddresses one or more aspects of manufacture, pre-incorporationverification, and data collection albeit not necessarily simultaneouslyin the same production station or based on a design that lends itself tomanufacturing products incorporating technology in a skilled areawithout the need of specialized technical capabilities at themanufacturing plant.

Thus, a preferred approach generally includes electronic collection andstorage, in a server, of substantially all information, includingmanufacturing data, software, instructions, and specifications used,generated, and updated and making such information accessible tomultiple production stations in the manufacturing plant as well as,preferably, to the company headquarters. The preferred approach furtherincludes a production station adapted to guide the relativelylow-skilled operator in the manufacture of the product even when theproduct incorporates technology in a high-skilled area.

To illustrate various aspects of the present invention, FIG. 1 is ablock diagram of a production station 102 according to one embodiment ofthe invention. The production station 102 is included in a manufacturingsystem typically owned and operated by a company. The manufacturingsystem as described herein refers to the system at the company and itsmanufacturing plant or the manufacturing plant of a CM. Themanufacturing system does not extend to a system used by a supplier ofunits, nor does it extend to a system used by a customer of the company.

The production station 102 comprises a data retrieval component 104, adata access component 106, a data verification component 108, a datawriting component 110, a data generation component 112, and, optionally,an interface component 114. In some implementations, the productionstation 102 may include a PC (personal computer) or other computerizedsystem. One or more components of the station 102 may be automated,i.e., require input or supervision by a human being (e.g., an operator).Alternatively, one or more components of the station 102 may beautomatic, i.e., require no input or supervision by the operator. As afurther alternative, one or more components of the station 102 may beperformed manually, for example, retrieving and storing data on thetraveler card.

The data retrieval component 104 is operative to retrieve data from oneor more units 118 a through 118 n. Each unit 118 may include a component(e.g., an integrated circuit), a subassembly, or a partially assembledproduct, depending, for example, on the position of the productionstation 102 in the manufacturing flow. In some embodiments, the dataretrieval component 104 may include any input device adapted to retrievedata by manual input (e.g., typing) or automated input (e.g., selectionfrom a menu by the operator or by recognition of the operator's voice),or a combination thereof. Examples of input devices may include ascanner or a bar code reader, a user input device, such as a keyboard, akey pad, a pointing device such as a mouse or the like.

The retrieval is accomplished by operatively connecting the units 118 athrough 118 n to the retrieval component 104 via communications links120 a through 120 n. In some embodiments, one or more of thecommunications links 120 comprises an optical link, for example, thelink established using a scanner or bar code reader. In someembodiments, one or more of the communications links 120 comprise a datacable, for example, a serial RS-232 cable, a cable including a parallelport, a USB (universal serial bus) or fire wire cable, a wirelessconnection such as Bluetooth, or the like. In some embodiments, thecommunications link is omitted (e.g., not necessary). For example, whenthe operator retrieves the data by looking at the unit after which theoperator enters the data by typing it in or by giving a voice command tothe data retrieval component 104, there is essentially no communicationslink between the unit, per se, and the data retrieval component 104.

The data access component 106 is operative to obtain data associatedwith each unit 118 and with the product to be assembled from a server116. Access is obtained via a communications link 122. The dataassociated with the product may include top level product data, such asa top level part number and a top level serial number, the BOM, and adesired configuration revision, i.e., the correct configuration revisionto be used in this product. The desired configuration revision may be apredefined or a required configuration revision. The desiredconfiguration revision may include a desired software revision orsoftware licensing option, which is associated, for example, with athroughput capacity of a radio being assembled. The desiredconfiguration revision may further include a calibration file orbranding data, for example, identifying whether the product is toinclude OEM branding, standard company branding, or no branding. Thedata associated with the unit 118 may include a supplier part number, acompany part number, a CM (contract manufacturer) part number, a serialnumber, an actual configuration revision, a desired configurationrevision, a calibration file, branding data, and the like.

The communications link 122 may include a LAN (local area network), aWAN (wide area network), an optical fiber, a microwave link, Ethernet,the Internet, Wi-Fi, a private line, a leased line, or the like. In someembodiments, the communications link 122 may include a firewall, a VPN(virtual private network), and it may be further adapted to restrictaccess to select users (e.g., on an individual basis or on a basis ofjob function).

As illustrated in FIG. 1, the production station 102 interfaces with theserver 116. However, the server 116 is not included as part of theproduction station 102 itself. A server typically functions as a datarepository and data service system. Such system therefore may include aserver, a database, a data storage, a data retrieval device, or acombination thereof. The server 116 may comprise one or more servers.For example, the server 116 may comprise a PLM (product lifecyclemanagement) server. The PLM server may in turn include an ERP(enterprise resource planning) server, a CRM (customer relationshipmanagement) server, an SCM (supply chain management) server, and thelike. Examples of such servers include server hardware and softwarepromoted by companies such as Agile Software Corporation, OracleCorporation, SAP AG, SAP America, Inc., Autodesk, Inc., and others.

The server 116 may further include an LIA (licensing informationapplication) server. The LIA server or any other portion of the server116 may be developed by the company or by one or more of the CMs. TheLIA server may be used to track licensing of software, includingrevisions and configurations per customer of, for example, radiosoftware for microwave radios. Data associated with the tracking oflicensing includes license terms and options, which may depend on, forexample, a number of units manufactured or a radio capacity licensed bythe customer. The customer may upgrade its licensed radio capacity, forexample, from 4E1 to 8E1, in one or more configurations of manufacturedradios that the customer purchases.

The server 116 may also be adapted to store a variety of data associatedwith individual stages of the manufacturing process, including BOMs,configurations (e.g., software revision number or other revisionindication), test results, calibration files, data associated withproduction control, scheduling, workflow management, quality control,inventory, supply chain planning, and financials, such as a generalledger, accounts payable, etc. The server 116 may be further adapted tostore software, instructions, and specifications to be downloaded,installed, and executed on one or more components of the productionstation 102.

The data verification component 108 is operative to compare dataretrieved from the unit 118 with corresponding data obtained from theserver 116. The comparison may include verification of the actualconfiguration revision by comparison with the desired configurationrevision. Verification of the configuration revision (actual, desired,or both) may include comparing multiple configuration revision elements.For example, the verification may include checking whether the softwarerevision of the product (i.e., once processing at this productionstation is completed) matches the data obtained from the server. Thismay include, for instance, checking whether calibration files associatedwith the one or more units 118 are compatible among each other and matcha desired configuration associated with the top level product data. Theverification may further include checking whether the configuration ofthe one or more units 118 is consistent with the licensing informationassociated with the purchase order and shipping information obtainedfrom the server. An example of such checking includes whether thecountry of destination permits operation in the frequency band for whichthe manufactured microwave radio is, or is to be, configured.

The data verification component 108 is further operative to generate anoutput based on the comparison. The response may include a successoutput and a fail output. If the compared data fails to match or isotherwise incompatible, the data verification component 108 may stopfurther processing of the unit and generate the fail output. The failoutput may include an error message displayed to the operator. Examplesinclude an error message in text on a display, a visual error messagesuch as a change of color of a light from, for example, green to red, orfrom a light turned off to a blinking light. If the compared datamatches or is otherwise compatible, the data verification component 108optionally generates and outputs the success output, and the processingis permitted to proceed.

The data verification component 108 is also adapted to prevent a manualoverride and to guide the operator to take remedial action, if possible.The guidance may be via voice or visual prompt. For example, if thesoftware configuration revision is found to be undesirable (e.g.,incorrect, incompatible, incomplete), the operator may be guided to havethe unit reconfigured. Reconfiguration may be performed on a separateproduction station or on a production station configured to perform morethan one set of functions, including reconfiguration. In the latterembodiment, the data access component 106 may download softwarecompatible with the desired configuration from the server 116 forinstallation on the unit, as further described below. A unit 118 mayalso, or alternatively, have an undesirable configuration not capable ofremedying via software reconfiguration. Examples include a mechanicalsubassembly or other hardware unit, such as a top cover that includesOEM branding in the form of an embossed logo. The operator may then beguided to take remedial action by replacing that unit with a differentlyconfigured unit, such as a unit having standard or no branding.

The data writing component 110 is operative to write data in the server116 via communications link 124. Writing in the server may includestoring and copying. Such data may include data generated during theprocessing at the production station, such as an updated calibrationfile or an updated configuration revision. The data writing component110 is further operative to write data to each unit 118. Writing to theunit may include copying and installing. Such data may include softwaredownloaded by the data access component 106, the updated configurationrevision itself, a new or updated calibration file, or branding data.The data may be written to EEPROM (electrically erasable programmableread only memory) in the unit 118. For such purposes, the data writingcomponent 110 is operatively connected to the units 118 a through 118 nvia communications links 128 a through 128 n.

The data generation component 112 is operative to generate dataassociated with the units 118 or the product being manufactured. Datagenerated may include newly generated data, such as a new calibrationfile or new branding data. Data generated may further include updateddata, such as additions, deletions, and modifications to existing data(e.g., an updated calibration file). Data generated by the datageneration component 112 may be written in the server 116, to the unit118, or both by the data writing component 110.

The interface component 114 may be optional. It is communicativelycoupled with a one or more peripheral devices 126 via communicationslink 130 and operative to transfer data to and from such peripheraldevices 126. Peripheral devices 126 may include input devices, outputdevices, fixtures, and instruments. Examples of input devices include akeyboard, a key pad, a pointing device such as a mouse, a voicerecognition device, or a combination thereof. Examples of output devicesinclude a display and a light source. Such devices allow the operatorto, for example, select the remedial action to be taken in response toerror message displayed on the output device. A peripheral device 126may further include a printer, which allows the operator to, forexample, print data retrieved from the unit, accessed from the server,or both.

The interface component 114 may further be coupled to a peripheraldevice 126 comprising a fixture, for example, in a production stationconfigured to perform testing functions on a unit 118. An exampleincludes an intermediate frequency card fixture in which the unit 118may be disposed. The peripheral device 126 may further include aninstrument such as a spectrum analyzer, a power meter, a data logger, orthe like. Some embodiments may include peripheral devices operativelyconnected to other or multiple components of the production station 102.For example, a data logger may be operatively connected to the dataretrieval component 104 as well as to the writing component 110 and tothe data generation component 112. In such embodiments, part or all ofthe interface component 114 is included in such other component.Peripheral devices are not shown in FIG. 1.

Communications link 124 is substantially similar to communications link122, and communications links 128 and 130 are substantially similar tolink 120, described above.

The aforementioned server 116 is typically part of an infrastructure ofthe manufacturing system. Such infrastructure may be installed at theheadquarters or at the manufacturing plant of the company or one or moreof the CMs. In some embodiments, the server 116 comprises multipleservers, which may be installed at more than one location or operated bymore than one entity (e.g., by the company as well as one or more CMs).

As described earlier, the production station 102 may be configured toperform one or more functions of incoming inspection, assembly, testing,branding, and post functional testing. A production station 102configured as an incoming inspection station may be configured (viasoftware, instructions, and specifications installed and executing onsuch station) to inspect an incoming shipment. The shipment may includeunits of one or more types (e.g., part numbers or configurations) from asupplier. The inspection may include retrieving data from documentationassociated with the shipment, such as data on a hardcopy of a packingslip. The inspection may also, or alternatively, include uploading(e.g., writing) data in the server. For example, units that includetechnology in a skilled area may be received together with data inelectronic format associated with such units. Such electronic format maybe on a CD-ROM. The inspection may further include data verification.For example, a select number of units may be checked by retrieving dataassociated with such units from the units themselves (e.g., byretrieving data in EEPROM or from a label attached to such unit) andcomparing the retrieved data with the data uploaded in the server. Someor all such data verification may be performed automatically, in anautomated fashion, or manually.

A production station 102 configured as an assembly station may beconfigured to obtain data associated with the product to be assembled(e.g., the BOM) from the server, to verify that each unit is a correctunit by comparing data retrieved from the unit with data associated withthe obtained from the server prior to accepting such unit forincorporation into the product, generating assembly data, and writingsuch generated data to a unit incorporated in the product and/or in theserver. A method for assembling a product on a production stationconfigured as an assembly station is described in further detail inconnection with FIG. 4.

A production station 102 may further be configured as a testing station.Such testing station may be positioned in the process flow prior to orafter a production station configured as an assembly station. Forexample, testing may be performed on a unit following incominginspection but prior to incorporation of the unit into the productduring assembly. Testing may alternatively or additionally be performedon the unit following assembly. Testing may further be performed on afully assembled product, for example, as part of post functionaltesting. A production station 102 configured to perform post functionaltesting may be positioned as the last station in the manufacturing flowprior to the manufactured product being forwarded to finished goodsinventory (FGI) or to a shipping area.

A test station 102 may retrieve data from a unit (or multiple units iftesting is performed on, for example, the assembled product), obtaindata associated with the unit, units, and/or product from the server,and compare the data for verification purposes. Testing may furtherinclude interfacing with one or more peripheral devices, such as placingthe unit or product in a test fixture and measuring actual values of oneor more parameters (e.g., frequency) using an instrument such as aspectrum analyzer. Testing may further include recording such data to adata logger. Data generated during such testing may include new as wellas updated data. In some embodiments, a test station 102 may beconfigured to prompt the operator to perform a visual inspection, forexample, of branding external to the unit or the assembled product andto input the result to the test station via an input device such as akeyboard. The test station 102 may also be configured to write generatedtest data in the server 116, to one or more units 118 (e.g., to EEPROM),or both. The test station 102 may further be configured to display asuccess or fail output to the operator and, if necessary, to guide theoperator in possible remedial action to be taken.

The scope of testing may depend on the product being manufactured andthe extent of functions performed on the production station 102,including whether the production station 102 is, for example, a combinedassembly and testing station. Testing may include functional testing(e.g., intermediate frequency functional testing or radio frequencylocal oscillator testing), thermal testing, calibration, post functionaltesting, boundary scan testing, or in-circuit testing. Testing mayfurther be performed as part of remote troubleshooting by the company'sdevelopment engineers from a central production station 102. Moreover,testing may include testing the configuration of the production station102 itself, for example, by downloading and installing a differentrevision of software, specifications, and instructions for use on theproduction station.

A production station 102 configured as a branding station may verify theexisting branding of a unit or assembled product and add new ordifferent branding. As such, the branding station may retrieve actualbranding data from the unit or product, obtain desired branding datafrom the server, and compare the retrieved and the obtained data. If thedata fail to match or otherwise be compatible, the branding station mayadd branding if none exists. For example, the branding station may add alogo by attaching a unit comprising the logo to, for example, a cover ofthe product. If the branding is incorrect, the branding station mayguide the operator to remove existing branding or to add correctbranding on top of the incorrect branding, if possible. If not possible,the branding station may guide the operator to replace the unitcomprising the incorrect branding with a correctly branded unit.Depending on the product being manufactured, such replacement may not bepossible at the branding station itself, and the operator may be guidedto forward a product incorporating incorrect branding to a differentlyconfigured production station for removal and replacement of the unitwith the incorrect branding. The branding station may further beconfigured to generate branding data, such as new or updated data,during processing and to write the generated data to the unit orproduct, in the server, or both.

The manufacturing system may include multiple production stations 102.Examples include at least one production station 102 configured as eachof an incoming station, an assembly station, and a testing station atthe manufacturing plant, and at least one central production station 102at the company headquarters. In some embodiments, such centralproduction station 102 may be a combined station, for example, acombined central assembly and development station adapted to alsodevelop new revisions of software, instructions, and specifications foruse on the production station 102 (e.g., the production station 102configured as an assembly station) at the manufacturing plant.

The software, instructions, and specifications allow for a productionstation 102 to be configured to perform functions in addition to thosedescribed herein. For example, a production station 102 may beconfigured to also attach a label to a unit, such as a label including asoftware revision number or a customer specific part number. Aproduction station 102 may also be configured to perform functions otherthan those described herein. For example, a production station 102 maybe configured to perform ship-out functions such as guiding the operatorin customer and/or destination specific packaging and handling ofproduct to be shipped.

FIG. 2 is a block diagram illustrating the server 116 according to oneembodiment of the invention. As noted earlier, although the server 116is not a component of the production station 102, various components ofthe production station 102 obtain data from and write data in the server116. The server 116 is adapted to store data, some portions of which maycomprise read-only data 202 and other portions of which may compriseread-and-write data 206. For example, in some embodiments, theproduction station 102 may be adapted to have access only to read-onlydata stored in the server 116. Examples of read-only data includesupplier part number, company part number, CM part number, serialnumber, and revision of a unit such as of a mechanical subassembly whoserevision is not capable of being altered during manufacture (e.g.,during assembly). In addition, read-only data may include portions oftest results for a unit tested at a previous station in themanufacturing process. For example, in some embodiments, the productionstation 102 may be adapted to have access to, but not alter, testresults obtained at a production station preceding this productionstation 102 in the manufacturing process.

Some portions of the read-only data 202 may comprise restricted accessread-only data 204. Examples of such data include sales order data, suchas price, customer identification data, salesperson identification data(e.g., commission percentage), distributor identification data (e.g.,discount and annual commit volumes), and purchase order data. Thepurchase order data may be designated restricted access read-only data,because the company or the CM may view such data as having competitivevalue. Examples include supplier price, applicable discount from thesupplier, quantities purchased including cumulative quantities, costedBOM data, and other data that include financial amounts or terms.

Additionally or alternatively, some portions of the data stored in theserver 116 may comprise read-and-write data 206. Examples of such datainclude calibration files, revisions of software and configurations, toplevel part number, top level serial number, OEM branding (also known asprivate labeling) data, and shipping record data. In some embodiments,portions of the read-and-write data 206 may comprise restricted accessread-and-write data 208. Examples include defect rates, causes ofdefects, and as-yet unreleased software revisions being developed andtested at the company headquarters. Access to such data may berestricted to management, financial controllers, design engineers, etc.The access may be restricted because of the potential contractualconsequences of the data (e.g., data that affects product warranties),because the data includes trade secrets or sensitive informationassociated with the customer, or for other reasons.

In some embodiments, some data in the server 116 is restricted accessread-only or restricted access read-and-write to some and read-only orread-and-write to other users or production stations. For example, newrevisions of software, instructions, and specifications being developedat the company headquarters may be stored in the server 116 anddesignated read-and-write data with restricted access to developmentengineers. Upon release to the manufacturing plant, such new revisionsmay be designated read-only data in the server 116. In addition, therestricted access designation may be removed or changed to include, forexample, some or all users or stations at the manufacturing plant.Access to and retrieval of restricted access data may be implemented onthe production station (e.g., on an assembly station 102 or on a PC usedfor development at the company headquarters), for example, by the use ofusername and password.

FIG. 3 is a flow diagram of a method for manufacturing productsaccording to one embodiment of the invention. This method illustrates amethod that may be performed by a production station 102 in mostconfigurations. According to the method, the processing of a unit at theproduction station 102 starts at step 302 by accessing the server 116 toobtain data associated with the product to be assembled. Such data mayinclude the BOM. At step 304, the production station 102 accesses theserver 116 to obtain data associated with a particular unit beingprocessed. Such data may include part number, serial number,configuration revision, branding data, calibration file, and so forthdepending on the processing to be performed at the production station,including depending on the configuration of the production station. Insome embodiments, steps 302 and step 304 may be performed by accessingthe server 116 once.

At step 306, the operator retrieves or otherwise inputs data from theunit. Retrieval may include using a scanner or bar code reader. Inputmay include entering the data via keyboard, key pad, or a pointingdevice such as a mouse. The retrieved data typically includes at leastthe data corresponding to the data obtained at step 304. At step 308,the retrieved data is compared with the obtained data. The retrieveddata is compared against the obtained data at least twice. First, theretrieved data is compared with the obtained data associated with theunit to verify that the two data sets reflecting the actualconfigurations match. Second, the retrieved data is compared with theobtained data associated with the product to verify that the actualconfiguration of the unit is a correct configuration for the productbeing manufactured. If both comparisons are successful, a success outputmay be generated at step 310. A manual override at step 310 is typicallynot possible. If, however, at least one comparison fails or the datasets are otherwise incompatible, a fail output is typically generatedand displayed at step 312. If so, the processing of the unit at theproduction station typically stops. The production station 102 may guidethe operator to take remedial action, if possible.

If the data comparisons are successful, the unit is processed at step314. The nature and extent of the processing depends on the productbeing manufactured and the configuration of the production station. Aspart of the processing, data may be generated at step 316. Generation ofdata may include creating new data or updating existing data. Forexample, a calibration file for the product being manufactured maychange in response to the incorporation of the unit during processinginvolving assembly. At step 318, parts or all of the generated data maybe written in the server 116. The written data typically becomessubstantially instantly accessible to other production stations in themanufacturing system, typically production stations following thisparticular production station in the process flow.

At step 320, data may be written to the unit, for example, in EEPROM.The data may include parts or all of the generated data, the obtaineddata, or both. The obtained data may include obtained data associatedwith the products, such as top level product data, obtained dataassociated with the unit, such as the desired configuration revision, ora combination of both.

Following step 320, in some embodiments, the method may return to step304. Examples of such embodiments may include methods performed at aproduction station configured to process a plurality of units. In such amethod, the data associated with the product to be produced, i.e., step302, may be performed only once for two or more units.

In some embodiments, processing at step 314 may include more than onetype of function. For example, processing may include assembly as wellas testing. In such embodiments, steps 314 through 320 may be performedonce per type of processing. For example, steps 314 through 320 may beperformed on the unit once for assembly and thereafter again fortesting.

Some steps may be optional. For example, some production stations 102may be configured such that no data is generated. In such embodiments,steps 316, 318 and 320 may be optional. In some embodiments,substantially all steps in the method may be optional. For example, in amethod performed on a production station 102 configured as an incominginspection station, the method may comprise only steps 306 and 314. Atstep 306, for example, a CD-ROM with supplier data associated with aunit that incorporates technology in a skilled area may be retrievedfrom the incoming shipment (although not literally from the unitsthemselves). At step 314, processing of the unit amounts to uploadingthe supplier data in the server.

The unit may fail at one or more of the steps in the method. Forexample, the unit may be unresponsive to retrieval of data at step 306.In such an event, the method may proceed to step 312, at which an errormessage is typically generated and the processing stops. The flowchartin FIG. 3 does not include all possible situations in which the methodmay proceed to step 312. However, those skilled in the art willrecognize that multiple such events are possible. The unit failing insome manner at a step in the method may be returned to the supplier, bediscarded, or be forwarded to another production station fortroubleshooting, for a replacement of one or more componentsincorporated in the unit, for a software update or upgrade, be returnedto FGI, or be otherwise disposed of (not shown in FIG. 3). In someconfigurations of the production station 102, steps in addition to thoseillustrated in FIG. 3 may be performed.

FIG. 4 is a flow diagram of a method for assembling products accordingto one embodiment of the invention. Thus, in this method, the productionstation 102 is configured to perform assembly functions. According tothis method, the assembly starts at step 402 by accessing the server 116to obtain data associated with the product to be assembled. Such datamay include top level product data and the BOM. At step 404, adetermination is made whether the accessed data includes top levelproduct data, such as top level serial number and top level productnumber. If the accessed data does not include such top level productdata, at step 406, the top level product data may be generated. In somemethods, the determination is made automatically. An example includes amethod in which software running on the station 102 makes thedetermination. In some methods, the determination may be made in anautomated fashion. An example includes a method in which data obtainedfrom the server is displayed to the operator, and the operator isallowed to make the determination, i.e., determine whether the top leveldata is complete, accurate, and the like. In yet some methods, theoperator is allowed to make determination based on information availablefrom sources separate from the assembly station 102. For example, theoperator may make the determination using his own judgment based onhardcopy information such as the traveler card. A manual determinationoperation may also be made, for example, in a method in which step 302is omitted, the server is inaccessible at step 402, or the like. Invarious embodiments, a combination of automated and manual determinationmay be used.

If, at step 402, the top level product data does not exist, top levelproduct data may be generated at step 406. The data may not exist if itis, for example, incomplete, or inconsistent or incompatible with otherdata. The generation may be automatic. For example, the assembly stationmay generate the top level serial number as the next available number.The generation may be automated. The operator may, for example, beprompted to input a top level serial number within a certain range ofacceptable numbers, to select a top level part number from a menu, or toapprove to a number proposed by the assembly station 102. In variousembodiments, a combination of automated and manual generation may beused.

At step 408, the operator retrieves or otherwise inputs data from theunit. Retrieval may include using a scanner or bar code reader. Inputmay include entering the data via keyboard, key pad, or a pointingdevice such as a mouse. The retrieved data typically includes serialnumber, part number, configuration revision, and calibration file. Atstep 410, data associated with the unit is obtained from the server. Theobtained data typically includes at least the data corresponding to theretrieved data. At step 412, the retrieved data is compared with theobtained data. If the data match or are otherwise compatible, a successoutput may be generated at step 414. A manual override at step 414 istypically not possible. If, however, the data do not match or areotherwise incompatible, a fail output is typically generated anddisplayed at step 416, and the assembly typically stops. The assemblystation 102 may guide the operator to take remedial action, if possible.

If the data match or are otherwise compatible, the unit is accepted forincorporation into the product at step 418. Assembly data may also begenerated. Generation may include creating the data or updating existingdata. For example, the calibration file for the product being assembledmay change in response to the incorporation of the unit. If so, thecalibration file associated with the top level product data may begenerated at step 418 and written in the server 116. The written datatypically becomes substantially instantly accessible to other productionstations in the manufacturing system. Examples of such stations includesubsequent production stations such as test or branding stations.

At step 420, a determination is made whether to incorporate another unitinto the product. If so, the method repeats from step 408 for the nextunit until all units to be incorporated have been accepted or otherwiseprocessed.

At step 422, the accepted units may be actually incorporated into theproduct. In some embodiments, each unit may be incorporated into theproduct at the step at which it is accepted. However, in someembodiments, the product may be designed such that two or more units areto be assembled together such as assembly jointly, at the same time, orin parallel. In other embodiments, the software, instructions, andspecifications installed on the assembly station 102 may be adapted suchthat some units are to be incorporated upon acceptance and others atstep 422.

At step 424, the assembled product may be tested. Step 424 may beoptional. For example, step 424 may be included only in embodiments inwhich the assembly station 102 includes a testing component 114. In someembodiments, even though the assembly station 102 includes the testingcomponent 114, some or all testing of the assembled product may beperformed at a production station other than the assembly station 102.If step 424 is included in the method and testing is performed, testdata may be generated in step 426. Such test data may include actualmeasured values of all tested parameters for each test run.

In some embodiments, parts or all generated assembly data and,optionally, test data may be written in the server at the step at whichsuch data is generated, i.e., at step 418, step 426, or both.Alternatively, parts of or all such data may written in the server atstep 428.

Following step 428, the assembled product is forwarded to the nextstage, if any, in the manufacturing process. Examples of the next stageinclude a calibration station, and an OEM branding station. In somemanufacturing systems, the assembly station 102 comprises the finalproduction station, and the next stage may be FGI (finished goodsinventory) or a shipping area. Such steps following step 428 are notshown in FIG. 4.

The unit or the assembled product may fail processing at one or more ofthe steps in the method. For example, the unit may be unresponsive toretrieval of data at step 408. In such an event, the method may proceedto step 416, at which an error message is typically generated and theassembly stops. The flowchart in FIG. 4 does not include all possiblesituations in which the method may proceed to step 416. However, thoseskilled in the art will recognize that multiple such events arepossible. The unit failing processing in some manner at a step in themethod may be returned to the supplier, be discarded, or be forwarded toa production station for troubleshooting, for a replacement of one ormore components incorporated in the unit, for a software update orupgrade, be returned to FGI, or be otherwise disposed of (not shown inFIG. 4).

In some methods, steps 402 through 406 may be omitted. In some methods,steps 402 through 406, steps 422 through 428, or another combination ofsteps may be performed by one or more separate production stations.

Although methods for a production station configured other than ingeneral (FIG. 3) and as an assembly station (FIG. 4) are not explicitlydescribed herein, those skilled in the art will recognize that a numberof variations are possible.

In sum, the present invention contemplates various design approaches toaddress manufacture of products incorporating technology in skilledareas. Preferably, these include storing data in a server such that thedata is readily accessible to various production stations used in themanufacturing process. Although the present invention has been describedin considerable detail with reference to certain preferred embodimentsthereof, other embodiments are possible. Therefore, the spirit and scopeof the appended claims should not be limited to the description of thepreferred embodiments contained herein.

We claim:
 1. A production station for processing a product to bemanufactured, the product including two or more units, the productionstation comprising: a data retrieval component configured to retrievedata from a first unit of the two or more units to be included in theproduct, the data from the first unit including installed softwareinformation regarding software installed on the first unit; a dataaccess component operative to obtain, from a server, data associatedwith the first unit, the associated data including desired softwareinformation; a data verification component operative to compare theretrieved data with the obtained data to verify that the softwareinstalled on the first unit is acceptable based on a comparison with thedesired software information, and to generate an output based on thecomparison, the output indicating whether the first unit should beaccepted for processing and included in the product, further processingof the first unit being allowed based on the output; and a data writingcomponent operative to write new software to the first unit if theverification of the data verification component indicates that thesoftware installed on the first unit is not acceptable.
 2. Theproduction station of claim 1, wherein the installed softwareinformation indicates a configuration of the software installed on thefirst unit.
 3. The production station of claim 2, wherein the dataverification component is operative to compare the configuration of thesoftware installed on the first unit to a configuration of desiredsoftware indicated in the desired software information.
 4. Theproduction station of claim 3, wherein the data writing component beingoperative to write new software to the first unit comprises the datawriting component being operative to reconfigure the software installedon the first unit.
 5. The production station of claim 1, wherein theinstalled software information indicates a version of the softwareinstalled on the first unit.
 6. The production station of claim 5,wherein the data verification component is operative to compare theversion of the software installed on the first unit to a desired versionindicated in the desired software information.
 7. The production stationof claim 6, wherein the data writing component being operative to writenew software to the first unit comprises the data writing componentbeing operative to update the software installed on the first unit tothe desired version indicated in the desired software information. 8.The production station of claim 1, in which the data retrievalcomponent, the data access component, and the data verificationcomponent are together operative to perform a production function. 9.The production station of claim 8, wherein the production functionincludes one or more of incoming inspection, assembly, testing,branding, and post functional testing of the manufactured product. 10.The production station of claim 8, wherein the data access component isfurther operative to obtain from the server software, instructions, andspecifications associated with the production function and wherein thedata retrieval component, the data access component, and the dataverification component are further operative to execute such obtainedsoftware, instructions, and specifications, the software, instructions,and specifications having been developed and written in the server. 11.The production station of claim 10, wherein the data access component isfurther operative to initiate obtaining the software, instructions, andspecifications from the server.
 12. The production station of claim 10,wherein the data access component is further configured to download thesoftware, instructions, and specifications from the server in responseto a download command initiated remotely.
 13. A method for processing aproduct to be manufactured, the product including two or more units, themethod comprising: obtaining, from a server, data associated with afirst unit of the two or more units to be included in the product, thedata from the server including desired software information; retrievingdata from the first unit, the data from the first unit includinginstalled software information regarding software installed on the firstunit; comparing the retrieved from the unit with the data obtained fromthe server to verify that the software installed on the first unit isacceptable based on a comparison with the desired software information;generating an output based on the comparison, the output indicatingwhether the first unit should be accepted for processing and included inthe product, further processing of the first unit being allowed based onthe output; and, writing new software to the first unit if theverification of the data verification component indicates that thesoftware installed on the first unit is not acceptable.
 14. The methodof claim 13, wherein the installed software information indicates aconfiguration of the software installed on the first unit.
 15. Themethod of claim 14, wherein comparing the retrieved from the unit withthe data obtained from the server comprises comparing the configurationof the software installed on the first unit to a configuration ofdesired software indicated in the desired software information.
 16. Themethod of claim 14, wherein writing new software to the first unitcomprises reconfiguring the software installed on the first unit. 17.The method of claim 13, wherein the installed software informationindicates a version of the software installed on the first unit.
 18. Themethod of claim 17, wherein comparing the retrieved from the unit withthe data obtained from the server comprises comparing the version of thesoftware installed on the first unit to a desired version indicated inthe desired software information.
 19. The method of claim 18, whereinwriting new software to the first unit comprises the data writingcomponent being operative to update the software installed on the firstunit to the desired version indicated in the desired softwareinformation.